RIGHT HAND NON-RATCHETING

LOWER UNIT
Section 6A – Right Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications Pinion Gear and drive shaft . . . . . . . . . . . . 6A-23
(Standard Rotation) . . . . . . . . . . . . . . . . . . . . . . 6A-1 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-26
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . 6A-27
Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Reassembly and Installation
Gear Housing (Drive Shaft) Standard Rotation . . . . . . . . . . . . . . . . . . . . . . . 6A-27
(Standard Rotation) . . . . . . . . . . . . . . . . . . . . . . 6A-6 Drive Shaft Needle Bearing . . . . . . . . . . . . 6A-27
Gear Housing (Prop Shaft) Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . 6A-28
(Standard Rotation) . . . . . . . . . . . . . . . . . . . . . . 6A-8 Forward Gear . . . . . . . . . . . . . . . . . . . . . . . . 6A-31
General Service Recommendations . . . . . . . 6A-10 Forward Gear Bearing Race . . . . . . . . . . . 6A-32
Removal, Disassembly, Cleaning Driveshaft and Pinion Gear . . . . . . . . . . . . 6A-33
and Inspection – Standard Rotation . . . . . . . . 6A-11 Pinion Gear Depth/Forward Gear
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-11 Backlash/Reverse Gear Backlash . . . . . . 6A-35
Draining and Inspecting Gear Housing Clutch Actuator Rod . . . . . . . . . . . . . . . . . . 6A-39
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Shift Shaft Bushing . . . . . . . . . . . . . . . . . . . 6A-39
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-14 Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-39
Bearing Carrier and Propeller Shaft Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . 6A-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-16 Gear Lubricant Filling Instructions . . . . . . 6A-46
Shift Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-18 Installing Gear Housing to Driveshaft
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . 6A-20 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-46 6
Clutch Actuator Rod . . . . . . . . . . . . . . . . . . 6A-23 Propeller Installation . . . . . . . . . . . . . . . . . . 6A-48
A
Gear Housing Specifications (Standard Rotation)
Forward Gear Reverse Gear
Ratio Pinion Depth
Backlash Backlash
0.025 in. (0.635 mm) 0.018 in. to 0.027 in.
With Tool 91-12349A2 (0.460 mm to 0.686 0.030 in. to 0.050 in.
1.87:1
using Disc #2 and mm) Pointer on line (0.762 mm to 1.27 mm)
Flat #7 mark #1
0.025 in. (0.635 mm) 0.015 in. to 0.022 in.
With Tool 91-12349A2 (0.38 mm to 0.56 mm) 0.030 in. to 0.050 in.
2.0:1
using Disc #2 and Pointer on line mark (0.762 mm to 1.27 mm)
Flat #7 #2
0.025 in. (0.635 mm) 0.018 in. to 0.023 in.
With Tool 91-12349A2 (0.46 mm to 0.58 mm) 0.030 in. to 0.050 in.
2.3:1
using Disc #2 and Pointer on line mark (0.762 mm to 1.27 mm)
Flat #7 #4

Gearcase Lubricant Capacity

All Ratios 22.5 fl. oz. (665.4 ml)

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RIGHT HAND NON-RATCHETING

Special Tools
1. Shift Shaft Bushing Tool 91-31107

2. Gear Housing Cover Nut Tool 91-61069

3. Bearing Carrier Removal Tool 91-46086A1 and Puller Bolt 91-85716

4. Slide Hammer Puller 91-34569A1

5. Bearing Removal and Installation Kit 91-31229A5. This kit contains the following
tools: Pilot 91-36571; Puller Rod 91-31229; Nut 11-24156; Puller Plate 91-29310;
Mandrel 91-38628; and Driver Rod 91-37323.

6. Pilot 91-36571

7. Puller Rod 91-31229 and Nut 91-24156

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 RIGHT HAND NON-RATCHETING

8. Puller Plate 91-29310

9. Mandrel 91-38628

10. Driver Rod 91-37323

11. Universal Puller Plate 91-37241

12. Cross Pin Tool 91-86642

13. Driveshaft Holding Tool 91-34377A1or 91-90094

14. Oil Seal Driver 91-31108

15. Forward Gear Bearing Tool 91-86943

16. Bearing Driver Cup 91-87120

17. Pinion Gear Locating Tool 91-12349A2 or 91-74776

90-855347R02 NOVEMBER 2002 Page 6A-3

RIGHT HAND NON-RATCHETING

18. Backlash Indicator Rod 91-78473

19. Dial Indicator 91-58222A1

20. Bearing Retainer Tool 91-43506

21. Bearing Preload Tool 91-14311A1

7
6
5
4

3
2

1 - Adaptor (N.S.S.)
2 - Bearing (N.S.S.)
3 - Washer (N.S.S.)
4 - Spring (24-14111)
5 - Bolt (10-12580)
6 - Nut (11-13953)
7 - Set Screw (10-12575)
8 - Sleeve (23-13946)

22. Mandrel 91-92788

23. Mandrel 91-15755

24. Dial Indicator Holder 91-89897

Page 6A-4 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

Notes:

90-855347R02 NOVEMBER 2002 Page 6A-5

RIGHT HAND NON-RATCHETING

Gear Housing (Drive Shaft)(Standard Rotation)

95
49
41 44
4.75 IN./120.65MM 46 45
TORPEDO DIA. 48 95
45 47
95
39 29
28
19
40 27
95
42 95
16
43 95

37
26 25
38 24
95 23
36
22
30
7

31
116 95 95
35
34
7 33 8 21
32 2
5 20
95
7 10
11 7
6 98

1918
10 4
12 33
3
95
9
13
14 1
15
7 Loctite 271
116
19 Perfect Seal 19
33 Loctite 680 Retaining Compound
17
95 2-4-C with Teflon
116 RTV 587 Silicone Sealer

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 RIGHT HAND NON-RATCHETING

Gear Housing (Drive Shaft)(Standard Rotation)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 GEAR HOUSING (BLACK)(BASIC)
2 1 CONNECTOR ASSEMBLY 50 5.5
3 2 DOWEL PIN
1 STUD (3-1/8 IN.) (LONG)
4 1 STUD (3-11/16 IN.) (X-LONG)
5 2 STUD (2-1/16 IN.)
6 1 STUD (3-3/8 IN.)
7 2 STUD (3-1/8 IN.)
8 1 FILLER BLOCK
9 1 ROLLER BEARING
10 2 ANODE
11 1 SCREW (M6 x 40)
12 1 NUT 60 7
1 PINION GEAR (1.87:1 - 15 TEETH)(150)(Part of 43-828174A2)
13 1 PINION GEAR (2:1 - 14 TEETH)(135)(Also part of 43-828176A2)
14 1 WASHER
15 1 NUT 75 101
16 AR SHIM SET
17 1 SCREW–drain (MAGNETIC) 60 7
18 1 SCREW–grease filler 60 7
19 2 WASHER
20 1 STA-STRAP
21 1 SHIFT SHAFT
22 1 O-RING
23 1 BUSHING ASSEMBLY 50 5.5
24 1 OIL SEAL
25 1 WASHER–rubber
1 DRIVE SHAFT (LONG)
26 1 DRIVE SHAFT (X-LONG)
27 1 ROLLER BEARING
28 1 CUP
29 1 RETAINER 100 135
30 1 WATER PUMP BASE
31 1 RETAINER
32 1 GASKET
33 1 O-RING
34 1 OIL SEAL
35 1 OIL SEAL
36 1 GASKET–lower
37 1 GASKET–upper
38 1 FACE PLATE
39 1 WATER PUMP BODY ASSEMBLY
40 1 INSERT
41 1 SEAL–rubber
42 1 lMPELLER
43 1 KEY
44 1 SCREW (#14-8 x 2-1/4 IN.) 35 4
45 2 WASHER
46 2 NUT 50 68
47 1 WASHER
48 1 NUT 50 68
49 1 SLEEVE

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RIGHT HAND NON-RATCHETING

Gear Housing (Prop Shaft)(Standard Rotation)

76 4.75 IN./120.65MM
TORPEDO DIA.

75

78

77 79
94

95
51
1

95

62 60
82

61

59
58

53
74 7 57
73 55
56
71 69 95
70 54
52
68
95 50
67
66
95
65 82
87
63
64

72

7 Loctite 271 95 95

82 Premium Gear Lubricant 82

94 Anti-Corrosion Grease
95 2-4-C With Teflon

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Gear Housing (Prop Shaft)(Standard Rotation)

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 GEAR HOUSING (BLACK)(BASIC)
50 1 CAM FOLLOWER
51 1 SHIFT CAM
52 1 ROD
1 FORWARD GEAR (1.87:1 – 15/28)(150)
53
1 FORWARD GEAR (2:1 – 14/28)(135)
54 AR SHIM SET
55 1 TAPERED ROLLER BEARING
56 1 CUP
57 1 NEEDLE BEARING
58 1 CLUTCH
59 1 CROSS PIN
60 1 DETENT PIN
61 1 SPRING
62 1 PROPELLER SHAFT
1 REVERSE GEAR (1.87:1 – 15/28)(150)
63
1 REVERSE GEAR (2:1 – 14/28)(135)
64 1 THRUST SPACER
65 1 THRUST RING
66 1 BALL BEARING
67 1 O-RING
68 1 BEARING CARRIER ASSEMBLY
69 1 ROLLER BEARING
70 1 OIL SEAL (INSIDE)
71 1 OIL SEAL (OUTSIDE)
72 1 KEY
73 1 TAB WASHER
74 1 COVER 210 285
75 1 TRIM TAB
76 1 SCREW (1-3/4 IN.) 25 34
77 1 SCREW (3/8-16 x 1 IN.) 30 41
78 2 WASHER
79 2 NUT 50 68

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General Service Recommendations

There may be more than one way to disassemble or reassemble a particular part,
therefore, it is recommended that the entire procedure be read prior to repair.
IMPORTANT: Read the following before attempting any repairs.
In many cases, disassembly of a sub-assembly may not be necessary until cleaning and
inspection reveals that disassembly is required for replacement of one or more compo-
nents.
Service procedure order in this section is a normal disassembly-reassembly sequence.
It is suggested that the sequence be followed without deviation to assure proper repairs.
When performing partial repairs, follow the instructions to the point where the desired
component can be replaced, then proceed to the reassembly and installation of that com-
ponent in the reassembly part of this section. Use the Table of Contents to find correct
page number.
Threaded parts are right hand (RH), unless otherwise indicated.
When holding, pressing or driving is required, use soft metal vise jaw protectors or wood
for protection of parts. Use a suitable mandrel (one that will contact only the bearing race)
when pressing or driving bearings.
Whenever compressed air is used to dry a part, be sure that no water is present in air line.
BEARINGS
Upon disassembly of gear housing, all bearings must be cleaned and inspected. Clean
bearings with solvent and dry with compressed air. Air should be directed at the bearing
so that it passes through the bearing. DO NOT spin bearing with compressed air, as this
may cause bearing to score from lack of lubrication. After cleaning, lubricate bearings with
Premium Gear Lubricant. DO NOT lubricate tapered bearing cups until after inspection.
Inspect all bearings for roughness, catches and bearing race side wear. Work inner bear-
ing race in-and-out, while holding outer race, to check for side wear.
When inspecting tapered bearings, determine condition of rollers and inner bearing race
by inspecting bearing cup for pitting, scoring, grooves, uneven wear, imbedded particles
and/or discoloration from overheating. Always replace tapered bearing and race as a set.
Roller bearing condition is determined by inspecting the bearing surface of the shaft that
the roller bearing supports. Check shaft surface for pitting, scoring, grooving, imbedded
particles, uneven wear and/or discoloration from overheating. The shaft and bearing must
be replaced, if the conditions described are found.
SHIMS
Keep a record of all shim amounts and location during disassembly to aid in reassembly.
Be sure to follow shimming instructions during reassembly, as gears must be installed to
correct depth and have the correct amount of backlash to avoid noisy operation and pre-
mature gear failure.
SEALS
As a normal procedure, all O-rings and oil seals SHOULD BE REPLACED without regard
to appearance. To prevent leakage around oil seals, apply Loctite 271 to outer diameter
of all metal case oil seals. When using Loctite on seals or threads, surfaces must be clean
and dry. To ease installation, apply 2-4-C with Teflon on all O-rings. To prevent wear, apply
2-4-C with Teflon on l.D. of oil seals.
To prevent corrosion damage after reassembly, apply 2-4-C with Teflon to external sur-
faces of bearing carrier and cover nut threads prior to installation.

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 RIGHT HAND NON-RATCHETING

Removal, Disassembly, Cleaning and Inspection – Standard

Rotation
Removal
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from
engine before removing gear housing from drive shaft housing.
1. Disconnect high tension leads from spark plugs and remove spark plugs from engine.

CAUTION
Gear housing MUST BE in NEUTRAL position and shift shaft MUST BE removed
from gear housing BEFORE propeller shaft can be removed from gear housing.
2. Shift engine into neutral position.
3. Tilt engine to full up position and engage tilt lock lever.
4. Bend tabs of propeller tab washer away from thrust hub (rear), then remove propeller
locknut, tab washer, thrust hub (rear), propeller and thrust hub (forward) from propel-
ler shaft.

a d
f

d e
b
51871
51866
a - Thrust Hub (Forward)
b - Propeller Shaft
c - Continuity Washer (If Equipped)
d - Rear Thrust Hub
e - Tab Washer
f - Propeller Nut

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RIGHT HAND NON-RATCHETING

5. Mark gear housing and trim tab so that trim tab can be reinstalled in the same position.
Remove plastic cap at rear edge of drive shaft housing, then unthread bolt that se-
cures trim tab and remove trim tab from gear housing.
6. Once trim tab is removed, remove bolt from inside of trim tab cavity.
7. Remove 2 locknuts from bottom middle of anti-cavitation plate.

a
b

51866

a - Bolt (Secures Trim Tab)

b - Bolt (Inside Trim Tab Cavity)
c - Locknuts and Washers

8. Remove locknut from the front gear housing mounting stud.

9. Loosen the side mounting locknuts. (DO NOT attempt to remove one nut before oppo-
site side is loosened sufficiently, or drive shaft housing could be damaged.)
10. Pull gear housing away from drive shaft housing as far as the loosened nuts (in Step
9) will allow, then remove loosened nuts. (DO NOT allow gear housing to fall, as it now
is free.)
11. Pull gear housing from drive shaft housing.

b
a

51879
a - Front Mounting Locknut
b - Side Mounting Locknut (One Each Side)

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Draining and Inspecting Gear Housing Lubricant

1. Place gear housing in a suitable holding fixture or vise with the drive shaft in a vertical
position.
NOTE: Drain and Fill screws may be located on the starboard side of gearcase on later
models.
2. Position a clean drain pan under gear housing and remove Fill and Vent screws from
gear housing.

51871
a - Fill Screw
b - Vent Screw

3. Inspect gear lubricant for metal particles. Presence of a small amount of fine metal
particles (resembling powder) indicates normal wear. Presence of larger particles (or
a large quantity of fine particles) indicates need for gear housing disassembly and
component inspection.
4. Note the color of gear lubricant. White or cream color indicates presence of water in
lubricant. Check drain pan for water separation from lubricant. Presence of water in
gear lubricant indicates the need for disassembly and inspection of oil seals, seal sur-
faces, O-rings and gear housing components.
NOTE: Gear lubricant drained from a recently run gearcase will be a light chocolate brown
in color due to agitation/aeration. Oil which is stabilized will be a clear yellow brown in col-
or.

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RIGHT HAND NON-RATCHETING

Water Pump
CLEANING AND INSPECTION
1. Clean all water pump parts with solvent and dry with compressed air.
2. Inspect water pump cover and base for cracks and distortion (from overheating).
3. Inspect face plate and water pump insert for grooves and/or rough surfaces.
IMPORTANT: When completing gear housing repairs that require removal of water
pump impeller, it is recommended that the impeller be replaced. However if it is
necessary to re-use impeller, DO NOT install in reverse to its original rotation, or
premature impeller failure will occur.
4. Inspect impeller side seal surfaces and ends of impeller blades for cracks, tears and
wear. Replace impeller if any of these conditions are found.
5. Inspect impeller bonding to impeller hub.
6. Inspect impeller for glazed or melted appearance (caused by operation without suffi-
cient water supply). Replace impeller if any of these conditions exist.
IMPORTANT: It is recommended that all seals and gaskets be replaced (as a normal
repair procedure) to assure effective repair.
REMOVAL AND DISASSEMBLY
1. Slide rubber centrifugal slinger up and off drive shaft.
2. Remove water tube guide and seal from water pump cover. Retain guide for reas-
sembly and discard seal.
3. Remove (and retain) 3 nuts, one bolt and all washers which secure water pump cover
to gear housing.
4. Using 2 pry bars, lift water pump cover up and off drive shaft.

b
51874

c
51874
a - Water Tube Guide
b - Water Tube Seal
c - Nuts, Bolt and Washers To Be Removed

5. Inspect water pump cover and insert, as outlined in Cleaning and Inspection.

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 RIGHT HAND NON-RATCHETING

6. If inspection of water pump insert determines that replacement is required, follow Step
“a” or “b” to remove insert from water pump cover.
NOTE: Try Step “a” first. If insert cannot be removed with Step “a,” use Step “b”.
a. Drive water pump insert out of water pump cover with a punch and hammer.

51874
b. Drill two 3/16 in. (4.8mm) diameter holes through the top of water pump cover (but
not through insert). Drive insert out of cover with a punch and hammer.

51873
a - Drill Two Holes at These Locations

7. Remove impeller from drive shaft. (It may be necessary to use a punch and hammer
to drive impeller upward on drive shaft. In extreme cases, it may be necessary to split
hub of impeller with a hammer and chisel.)
8. Once impeller is removed, remove impeller drive key from drive shaft.
9. Remove water pump face plate and both gaskets (one above and below face plate)
from water pump base.

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RIGHT HAND NON-RATCHETING

10. Using 2 pry bars, positioned and padded as shown, lift water pump base up and off
drive shaft.

a
51874
a - Pads

11. Remove (and discard) O-ring from O-ring groove on water pump base.
12. Using a screwdriver, pry oil seals out of water pump base from gear housing side of
base.
Bearing Carrier and Propeller Shaft Removal
CAUTION
Gear housing MUST BE in NEUTRAL position, and shift shaft MUST BE removed
from gear housing before propeller shaft can be removed from gear housing.
1. Place gear housing in a suitable holding fixture with propeller shaft in a horizontal posi-
tion.
2. Use the Shift Shaft Bushing Tool to unthread shift shaft bushing. (DO NOT remove
bushing from shift shaft at this time.)
IMPORTANT: Prior to removal of shift shaft from gear housing, recheck that gear
housing is in NEUTRAL position.
3. Bend cover nut lock tab out of cover nut recess.

a c b
51874
51865
a - Shift Shaft Bushing Tool (91-31107)
b - Punch
c - Tab of Tab Washer

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4. Remove gear housing cover nut with Cover Nut Tool.

51866
a - Cover Nut Tool (91-61069)

5. After cover nut has been removed, remove lock tab washer from gear housing.

CAUTION
Once bearing carrier is removed from gear housing, extreme care MUST BE taken
not to apply any side force on propeller shaft. Side force on propeller shaft may
break the neck of the clutch actuator rod.
6. Use long Puller Jaws and Puller Bolt to remove bearing carrier. (Use propeller thrust
hub to maintain outward pressure on puller jaws.)
NOTE: When bearing carrier is removed from gear housing, the bearing carrier alignment
key will come out with it.
7. With gear housing in NEUTRAL, pull shift shaft out of gear housing. If necessary, use
a pliers to pull shift shaft out of gear housing. If pliers are used to pull shift shaft out,
wrap a strip of soft metal (aluminum) around splines before clamping pliers. DO NOT
turn shaft (clockwise OR counterclockwise) while pulling shaft out.

d
a
b

51867
c
51867

a - Long Puller Jaws d - Shift Shaft Bushing

(91-46086A1) e - Shift Shaft
b - Puller Bolt (91-85716)
c - Thrust Hub

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CAUTION
Propeller shaft, cam follower and shift cam, in most cases, will come out of gear
housing by simply pulling outward on propeller shaft. DO NOT FORCE shaft side-
ways or ATTEMPT TO PULL with a slide hammer or any mechanical puller.
8. Remove propeller shaft, cam follower and shift cam by pulling shaft straight out of gear
housing. (DO NOT JERK propeller shaft.) If propeller shaft will not come out, proceed
with Step “a” or “b”, following:
a. Push the propeller shaft back into place against the forward gear. Visually inspect
location of shift cam by looking down shift shaft hole (illuminated with a flashlight).
If splined hole in shift cam is visible, reinstall shift shaft and rotate shift shaft to
NEUTRAL position. Remove shift shaft, then remove propeller shaft as instructed
in Step 8, immediately preceding.
b. Push propeller shaft back into place against forward gear. Slide bearing carrier
back into gear housing (to support propeller shaft). Place gear housing on its left
side (viewed from rear) and strike upper leading end of gear housing with a rubber
mallet. This will dislodge the shift cam from cam follower into a clearance pocket
in left side of gear housing. Remove bearing carrier and pull propeller shaft out
of gear housing.
NOTE: If Step 8-b was used to remove propeller shaft, the shift cam can be retrieved after
removal of forward gear.
Shift Shaft
CLEANING AND INSPECTION
1. Clean shift shaft and bushing with solvent and dry with compressed air.
2. Check shift shaft splines on both ends for wear and/or corrosion damage.
3. Inspect shift shaft for grooves at shift shaft bushing seal surface.
4. Inspect shift shaft bushing for corrosion damage.
5. Inspect shift shaft bushing oil seal for wear and/or cuts.
NOTE: Oil seal in shift shaft bushing should be replaced as a normal repair procedure.
DISASSEMBLY
1. Remove (and discard) shift shaft bushing oil seal by prying it out or driving it out with
a punch and hammer.
CLEANING/INSPECTION - BEARING CARRIER
IMPORTANT: It is recommended that all seals and O-rings be replaced (as a normal
repair procedure) to assure effective repair.
1. Clean bearing carrier with solvent and dry with compressed air.

CAUTION
DO NOT spin bearings dry with compressed air, as this could cause bearing to
score.
2. Bearing carrier propeller shaft needle bearing condition is determined by propeller
shaft bearing surface condition. (See Propeller Shaft Inspection.)
3. Inspect reverse gear to pinion gear wear pattern (should be even and smooth). If not,
replace reverse gear and pinion gear.

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4. Check clutch jaws on reverse gear for damage. Replace reverse gear, if damage is
found on clutch jaws.
5. Apply light oil to reverse gear bearing. Rotate reverse gear bearing while checking
bearing for rough spots and/or catches. Push in and pull out on reverse gear to check
for bearing side wear. Replace bearing if any of the listed conditions exist.
DISASSEMBLY - BEARING CARRIER
1. Remove and discard O-ring from between bearing carrier and thrust washer.
2. If inspection of reverse gear or reverse gear bearing determines that replacement of
gear or bearing is required, remove gear and bearing as follows:
a. Position bearing carrier in a soft jaw vise.
b. Use Slide Hammer (91-34569A1) and remove reverse gear.

51868
c. If reverse gear bearing remains attached to reverse gear, install Universal Puller
Plate and position puller plate, gear and bearing on a press with gear side down.
Use a suitable mandrel and press gear out of bearing.

a 51874
a - Universal Puller Plate (91-37241)
b - Mandrel

d. If reverse gear bearing has remained in bearing carrier, use slide hammer to re-
move bearing in the same method as was used to remove reverse gear (Step “b”).

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3. Propeller shaft oil seals can be removed by 1) using a pry bar, or 2) pressing seals
out when propeller shaft needle bearing is pressed out of bearing carrier.
4. If inspection of propeller shaft needle bearing determines that replacement of bearing
is required, use Universal Bearing Removal and Installation Tool (91-31229A1) to
press bearing and seals out of bearing carrier.
NOTE: Reverse gear must be removed from bearing carrier before propeller shaft needle
bearing can be removed.

51868 51871
a - Pry Bar
b - Propeller Shaft Needle Bearing
c - Mandrel
d - Oil Seals
Propeller Shaft
INSPECTION
1. Clean propeller shaft assembly with solvent and dry with compressed air.
2. Inspect bearing carrier oil seal surfaces for grooves. Run fingernail across seal sur-
face to check for groove. Replace shaft if groove is found.
3. Visually check bearing surfaces of propeller shaft for pitting, grooves, scoring, uneven
wear or discoloration (bluish color) from overheating. Replace shaft and correspond-
ing needle bearing if any of the above conditions are found. (Bearing carrier needle
bearing contacts propeller shaft just in front of oil seal surface. Forward gear bearing
contacts propeller shaft in front of sliding clutch splines.)
4. Inspect propeller shaft splines for wear and/or corrosion damage.

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5. Check propeller shaft for straightness. Use either method, following:

a. Place propeller shaft on balance wheels. Rotate propeller shaft and observe pro-
peller end of shaft for wobble. Replace shaft if any wobble is observed.
b b

a
c

51872
a - Balance Wheels
b - Bearing Surfaces
c - Watch for Wobble

b. Position the propeller shaft roller bearing surfaces on vee blocks. Mount a dial in-
dicator at front edge of propeller splines. Rotate propeller shaft. Dial indicator
movement of more than 0.006 in. (0.152 mm) (or noticeable wobble) is reason for
replacement.
b b

c a

51872
a - Vee Blocks
b - Bearing Surfaces
c - Measure with Dial Indicator at this Point

90-855347R02 NOVEMBER 2002 Page 6A-21

RIGHT HAND NON-RATCHETING

6. Inspect sliding clutch. Check reverse gear and forward gear clutch jaws. Rounded
jaws indicate one or more of the following:
a. Improper shift cable adjustment.
b. Improper shift habits of operators (shift from NEUTRAL to REVERSE gear too
slowly).
c. Engine idle speed too high (while shifting).
a

51865
a - Clutch Jaws

7. Check condition of cam follower. If it shows wear (pitting, scoring or rough surface),
replace cam follower and shift cam.
DISASSEMBLY
1. Remove shift cam from cam follower.
2. Insert a thin blade screwdriver or awl under first coil of cross pin retainer spring and
rotate propeller shaft to unwind spring from sliding clutch. DO NOT over-stretch
spring.

CAUTION
Detent pin is free and can fall out of sliding clutch. Care MUST BE taken not to lose
pin.
3. Detent pin is free and can be removed from sliding clutch at this time.
b
c
d

a
51864 e 51864
a - Awl
b - Cross Pin Retainer Spring
c - Detent Pin
d - Cross Pin
e - Sliding Clutch

Page 6A-22 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

4. Push cross pin out of sliding clutch and propeller shaft with Cross Pin Tool.
5. Pull sliding clutch off propeller shaft.
6. Pull cam follower and clutch actuator rod out of propeller shaft. DO NOT force cam
follower up-or-down or side-to-side when pulling from propeller shaft.

c d e
51864

b
51864
a - Cross Pin Tool (91-86642)
b - Cross Pin
c - Cam Follower
d - Clutch Actuator Rod
e - Propeller Shaft

7. Once cam follower and clutch actuator rod are removed from propeller shaft, lift rod
out of cam follower.
Clutch Actuator Rod
CLEANING AND INSPECTION
1. Clean clutch actuator rod in solvent and dry with compressed air.
2. Inspect actuator components for wear or damage. Replace components as required.
Pinion Gear and drive shaft
REMOVAL
1. Remove bearing retainer using Bearing Retainer Tool.

a
51865
a - Bearing Retainer
b - Bearing Retainer Tool (91-43506)

2. Place drive shaft Holding Tool (91-34377A1) over drive shaft splines.
3. Use a socket and flex handle to hold pinion nut. (Pad area of gear housing where flex
handle will make contact to prevent damage to gear housing.)
4. Use a socket and flex handle on drive shaft Holding Tool to loosen pinion nut. Remove
pinion nut and drive shaft Holding Tool.

90-855347R02 NOVEMBER 2002 Page 6A-23

RIGHT HAND NON-RATCHETING

5. Remove gear housing from vise and re-position it as shown. Be sure to use soft jaw
vise covers and clamp as close as possible to water pump studs.
6. Place a block of wood on gear housing mating surface. Use a mallet and carefully tap
gear housing away from drive shaft.

CAUTION
DO NOT strike gear housing hard with the mallet or allow gear housing to fall.

b a

51870

a - Wooden Block
b - Soft Jaw Vise Covers

7. Reach into gear housing and remove pinion gear and forward gear assembly.
8. After drive shaft is removed from gearcase, remove and retain shims that were lo-
cated under upper tapered drive shaft bearing.
9. If inspection determines that replacement of drive shaft tapered bearing is required,
remove bearing from drive shaft as follows:
a. Position drive shaft in a vise. DO NOT tighten vise jaws against shaft.
b. Strike shaft with a lead hammer; take care not to drop shaft.

51866
10. Remove 18 loose needles from outer race of drive shaft needle bearing.

Page 6A-24 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

11. If inspection of drive shaft needle bearing surface determines that replacement of
needle bearing is required, the 18 loose needle bearings previously removed must
be reinstalled in bearing race to provide surface for mandrel to drive against.
NOTE: FORWARD gear must be removed first BEFORE removing drive shaft needle
bearing.
IMPORTANT: Discard drive shaft needle bearing after removal. (Bearing cannot be
reused.)

51869
a - Mandrel (91-37263)
b - Pilot* (91-36571)
c - Driver Rod* (91-37323)
*From Bearing Removal and Installation Kit (91-31229A5)

CLEANING AND INSPECTION

1. Clean drive shaft, tapered bearing and race, and pinion gear with solvent. Dry with
compressed air. DO NOT allow drive shaft bearing to spin while drying.
2. Inspect pinion gear for pitting, grooves, scoring, uneven wear and/or discoloration
from overheating. Replace pinion gear, if any of the above conditions are found.
3. Inspect drive shaft needle bearing surface (area just above pinion gear splines) for
pitting, grooves, scoring, uneven wear and/or discoloration from overheating. Re-
place drive shaft and drive shaft needle bearing, if any of the preceding conditions are
found.
4. Inspect drive shaft to crankshaft splines for wear. Replace drive shaft if wear is exces-
sive.
5. Inspect tapered bearing race for pitting, grooves, scoring, uneven wear and discolor-
ation from overheating. Replace tapered bearing and race as a set, if any of the pre-
ceding conditions are found.
6. Inspect drive shaft for grooves where water pump base oil seals contact shaft. Re-
place drive shaft if grooves are found.

90-855347R02 NOVEMBER 2002 Page 6A-25

RIGHT HAND NON-RATCHETING

Forward Gear
REMOVAL AND DISASSEMBLY
NOTE: Forward gear can only be removed from gear housing after drive shaft and pinion
gear have been removed.
1. Reach into gear housing and lift out forward gear.
IMPORTANT: DO NOT remove tapered bearing or needle bearings from forward
gear, unless replacement of bearings is required. (Bearings cannot be reused after
they have been removed.)
2. If inspection determines that replacement of forward gear tapered bearing is required,
remove bearing from gear and bearing race from gear housing (tapered bearing and
race MUST BE replaced as a set), as follows:
a. Install Universal Puller Plate between forward gear and tapered bearing.
b. Place forward gear, bearing and puller plate on a press and press gear out of bear-
ing with a suitable mandrel.
c. Use Slide Hammer to remove forward gear tapered bearing race.

b c
a

51870 51865
d
a - Universal Puller Plate (91-37241)
b - Mandrel
c - Slide Hammer (91-34569A1)
d - Tapered Bearing Race

d. After forward gear tapered bearing race is removed from gear housing, lift out and
retain shims which were behind bearing race.
3. If inspection determines that replacement of propeller shaft needle bearings in for-
ward gear is required, remove bearing from gear as follows:
a. Clamp forward gear in a soft jaw vise securely.
b. From toothed-side of gear, drive propeller shaft needle bearings out of gear with
a punch and hammer.

Page 6A-26 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

CLEANING AND INSPECTION

CAUTION
DO NOT spin bearings dry with compressed air, as this could cause bearing to
score.
1. Clean forward gear and bearings with solvent and dry with compressed air.
2. Inspect gear teeth for pitting, grooves, scoring, uneven wear and for discoloration
(from overheating). Replace gear if any of these conditions are found.
3. Check clutch jaws on forward gear for damage. Replace forward gear if damage is
found.
4. Inspect tapered bearing race for pitting, grooves, scoring, uneven wear and discolor-
ation (from overheating). Replace tapered bearing (on forward gear) and race if any
of these conditions are found. (Always replace tapered bearing and race as a set.)
5. To determine condition of propeller shaft needle bearings (in forward gear), inspect
propeller shaft forward gear needle bearing surface as outlined in Propeller Shaft
Inspection.
Gear Housing
CLEANING AND INSPECTION
1. Clean gear housing with solvent and dry with compressed air.
2. Check gear housing carefully for impact damage.
3. Check for loose fitting bearing cups and needle bearings.
4. Inspect bearing carrier cover nut retainer threads in gear housing for corrosion dam-
age and/or stripped threads.

Reassembly and Installation Standard Rotation

Drive Shaft Needle Bearing
REASSEMBLY/INSTALLATION

CAUTION
If drive shaft needle bearing failure has occurred, and original bearing race has
turned in the gear housing, gear housing MUST be replaced. Loose fitting needle
bearing will move out of position and cause repeated failures.
1. Apply a thin coat of 2-4-C with Teflon to drive shaft needle bearing bore in gear
housing.
2. By way of propeller shaft cavity, place needle bearing in driveshaft bore with num-
bered side of bearing facing up driveshaft bore.

90-855347R02 NOVEMBER 2002 Page 6A-27

RIGHT HAND NON-RATCHETING

3. Install and seat needle bearing with the following tools: Puller Rod*, Nut*, Pilot*,
Plate*, and Mandrel (models with preloaded driveshaft use 91-38628*; models with
standard driveshaft use 91-92788). Pull bearing up into bore until it bottoms on gear
housing shoulder. (DO NOT use excessive force.)
*From Bearing Removal and Installation Kit (91-31229A5)

e
g
d

a
51869
a - Mandrel
b - Bearing
c - Pilot (91-36571)
d - Plate (91-29310)
e - Puller Rod (91-31229)
f - Hold
g - Nut (11-24156)

Bearing Carrier
REASSEMBLY
1. Place reverse gear on a press with gear teeth facing down.
IMPORTANT: The reverse gear thrust washer has a tapered outside diameter so
that one side is larger than the other. The larger outside diameter of washer must
be toward reverse gear.
2. Place thrust washer over gear with the larger outside diameter down toward gear.
3. Apply a light coat of Premium Gear Lubricant onto inside diameter of reverse gear ball
bearing.
4. Position ball bearing over gear (with numbered side of bearing up).

Page 6A-28 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

5. Press ball bearing onto gear with a suitable mandrel until firmly seated. (Be sure to
press only on inner race of bearing and that bearing is firm against gear.)
6. Apply a light coat of Premium Gear Lubricant onto outside diameter of propeller shaft
needle bearing.
7. Place propeller shaft needle bearing into aft end of bearing carrier with numbered side
toward aft end.
8. Use Mandrel and press needle bearing into bearing carrier.

a
c

51873
51872
a - Thrust Washer
b - Mandrel
c - Mandrel (91-15755)

9. Apply Loctite 271 to outer diameter of propeller shaft oil seals.

10. Place one seal on longer shoulder side of Oil Seal Driver with lip of seal facing away
from shoulder. Press seal into bearing carrier until seal driver bottoms against bearing
carrier.

51872
a - Oil Seal (Lip of Seal Down)
b - Oil Seal Driver (91-31108)
c - Seated

90-855347R02 NOVEMBER 2002 Page 6A-29

RIGHT HAND NON-RATCHETING

11. Place second seal on short shoulder side of seal driver with lip of seal toward shoulder.
Press seal into bearing carrier until seal driver bottoms against bearing carrier.

a
c

51872
a - Oil Seal (Lip of Seal Up)
b - Oil Seal Driver
c - Seated

12. Wipe off excess Loctite.

13. Apply a light coat of Premium Gear Lubricant onto the outside diameter of reverse
gear ball bearing.
14. Place bearing carrier over reverse gear and bearing assembly. Press bearing carrier
onto bearing.

51870
a - Mandrel
b - Seated

15. Place O-ring over bearing carrier and position it between bearing carrier and thrust
washer.
16. Lubricate oil seals and O-ring with 2-4-C with Teflon.

Page 6A-30 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

Forward Gear
REASSEMBLY
1. Place forward gear on a press with gear teeth down.
2. Apply a light coat of Premium Gear Lubricant onto the inside diameter of forward gear
tapered bearing.
3. Position forward gear tapered bearing over gear.
4. Press bearing onto gear until firmly seated. (Be sure to press only on inner race of
bearing and that bearing is firm against the gear.)
a

51869
a - Mandrel
b - Wooden Block

5. Apply a light coat of Premium Gear Lubricant to bore in center of forward gear.
6. Place one forward gear needle bearing on longer shoulder side of Forward Gear Bear-
ing Tool with numbered side of bearing toward shoulder. Press bearing into forward
gear until bearing tool bottoms against gear.

a
b

51873
a - Forward Gear Bearing Tool (91-86943)
b - Numbered Side of Needle Bearing

7. Place second needle bearing on short shoulder side of bearing tool with numbered
side of bearing toward shoulder. Press bearing into forward gear until bearing tool bot-
toms against gear.

90-855347R02 NOVEMBER 2002 Page 6A-31

RIGHT HAND NON-RATCHETING

Forward Gear Bearing Race

INSTALLATION
1. Place shims (retained from disassembly) into gear housing. If shims were lost or a
new gear housing is being used, start with approximately 0.010 in. (0.254 mm).
2. Apply a light coat of Premium Gear Lubricant to forward gear bearing race bore in gear
housing.
3. Position tapered bearing race squarely over bearing bore in front portion of gear
housing.
4. Place Bearing Driver Cup over tapered bearing race.
NOTE: A used propeller shaft is recommended for use in Step 5. If it is necessary,
however, to use the propeller shaft that will be installed in gear housing, the propeller
shaft must be disassembled. (Refer to Propeller Shaft Disassembly, preceding.)
5. Place propeller shaft into hole in center of Bearing Driver Cup.
6. Install bearing carrier assembly over propeller shaft and lower it into gear housing.
Bearing carrier acts as a pilot to assure proper bearing race alignment.
7. Thread a nut onto propeller shaft to protect propeller shaft threads.
8. Use a mallet to drive propeller shaft against bearing driver cup until tapered bearing
race is seated against shims.

a 51867
a - Tapered Bearing Race
b - Bearing Driver Cup (91-87120)
c - Shim(s)

9. Remove nut from propeller shaft, then remove bearing carrier and propeller shaft from
gear housing. Lift bearing driver cup out of gear housing.
10. Apply a light coat of oil on tapered bearing race, then place forward gear assembly
into forward bearing race.

Page 6A-32 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

Driveshaft and Pinion Gear

REASSEMBLY/INSTALLATION
1. Apply a light coat of Premium Gear Lubricant on l.D. of driveshaft tapered bearing.
2. Thread a used pinion nut onto end of driveshaft. Leave approximately 1/16 in. (2 mm)
of nut threads exposed. Driveshaft threads MUST NOT extend beyond nut or thread
damage could result while pressing.
3. Place bearing over driveshaft.
4. Using an old driveshaft bearing inner race or other suitable mandrel (which applies
pressing force on center bearing race only), press bearing onto shaft until seated.

c
d
e

a - Used Pinion Nut

b - Driveshaft
c - Tapered Bearing
d - Old Bearing Inner Race
e - Universal Puller Plate

5. Position pinion gear in gear housing below driveshaft bore with teeth of pinion gear
meshed with teeth of reverse gear.
6. Insert driveshaft into driveshaft bore while holding pinion gear. Rotate driveshaft to
align and engage driveshaft splines with pinion gear splines. Continue to insert drive-
shaft into gear housing until driveshaft tapered bearing is against bearing race.
NOTE: It is recommended that after final pinion depth is obtained, a new pinion nut be
installed. Clean pinion nut threads with Loctite 7649 Primer N before applying Loctite 271.
7. Place a small amount of Loctite 271 onto threads of pinion nut. Install flat washer and
nut on drive shaft with flat side of nut away from pinion gear. Hand tighten pinion nut.

90-855347R02 NOVEMBER 2002 Page 6A-33

RIGHT HAND NON-RATCHETING

8. Place shims (retained from disassembly) into gear housing. If shims were lost or are
not reusable (damaged), start with approximately 0.010 in. (0.254 mm).
9. Install bearing race and bearing retainer.

i
b c
h

d g

e 51867 f 51880
a - Driveshaft (rotate to engage splines with pinion gear)
b - Forward Gear Assembly
c - Pinion Gear
d - Washer (located above pinion nut)
e - Pinion Nut
f - Shims
g - Bearing Race
h - Bearing Retainer (Word “OFF” must be visible) Torque to 100 lb. ft. (135.5 Nm)
i - Bearing Retainer Tool (91-43506)

10. Use socket and flex handle to hold pinion nut (pad area where flex handle will contact
gear housing) while torquing nut.
11. Place Driveshaft Holding Tool over crankshaft end of drive shaft. Torque pinion nut
to 75 lb. ft. (101.5 Nm).

c
b a

d
a - Driveshaft Holding Tool (91-34377A1 or 91-90094)
b - Torque Wrench
c - Socket
d - Breaker Bar

IMPORTANT: Wipe any excess Loctite from pinion nut and pinion gear.

Page 6A-34 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

Pinion Gear Depth/Forward Gear Backlash/Reverse Gear Backlash

DETERMINING PINION GEAR DEPTH
NOTE: Read entire procedure before attempting any change in shim thickness.
IMPORTANT: Forward gear assembly must be installed in gear housing when
checking pinion gear depth or an inaccurate measurement will be obtained.
1. Clean the gear housing bearing carrier shoulder.
2. Install Bearing Preload Tool (91-14311A1) over driveshaft in sequence shown.
NOTE: Bearing Preload Tool (91-44307A1) may also be used. Follow instructions provided
with tool for proper installation.
h

g g

b
a

a - Adaptor
b - Bearing
c - Washer
d - Spring
e - Nut; thread nut all the way onto bolt
f - Bolt
g - Set Screw
h - Sleeve; Holes in sleeve must align with set screw

3. Align adaptor on driveshaft bearing pocket ledge.

4. With tool installed over driveshaft, tighten both set screws securely, making certain
to align sleeve holes to allow set screws to pass through.

90-855347R02 NOVEMBER 2002 Page 6A-35

RIGHT HAND NON-RATCHETING

5. Measure distance “a“ and increase that distance by 1 in. (25.4 mm) by turning bottom
nut away from top nut.

1 in. (25.4 mm)

b
a

c
51870
a - Distance
b - Adaptor
c - Ledge

6. Turn driveshaft clockwise 2 or more turns to seat driveshaft bearings.

7. Insert Pinion Gear Locating Tool into gear housing until it bottoms out on bearing car-
rier shoulder.
NOTE: Pinion Gear Locating Tool (91-12349A2) can be used. Use flat #7 and disc #2.
Follow instructions supplied with tool.
8. Determine pinion gear depth by inserting feeler gauge through access slot in pinion
gear shimming tool.
9. Clearance between locating tool and pinion gear should be 0.025 in. (0.64 mm).
10. If clearance is correct, leave Bearing Preload Tool on driveshaft for Determining For-
ward Gear Backlash, following.
11. If clearance is not correct, add (or subtract) shims at location shown to raise (or lower)
pinion gear. When reinstalling pinion nut, apply Loctite 271 on threads of nut and re-
torque pinion nut.

c b
d
a

c
a
24643
a - Pinion Gear Locating Tool (91-74776)
b - Feeler Gauge
c - Obtain 0.025 in. (0.64 mm) Clearance between Locating Tool and Pinion Gear
d - Add or Subtract Shims Here

NOTE: Bearing Preload Tool (91-14311A1) should remain installed on driveshaft after setting
pinion gear depth. It is required to properly check forward gear and reverse gear backlash.

Page 6A-36 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

DETERMINING FORWARD GEAR BACKLASH

IMPORTANT: Bearing carrier must be assembled to provide pilot for propeller shaft.
1. Insert propeller shaft into position in gear housing. (DO NOT place shift cam on
propeller shaft.)
2. Place bearing carrier into gear housing and thread cover nut tightly against bearing
carrier. (It is not necessary to torque cover nut against bearing carrier.)
3. Attach Bearing Carrier Removal Tool and Puller Bolt onto gear housing.
4. Torque puller bolt against propeller shaft to 45 Ib. in. (5 Nm). Turn driveshaft 10 revolu-
tions with the load applied to propeller shaft. This will seat forward gear bearing.

a d
b

c 51867
a - Propeller Shaft (DO NOT install shift cam)
b - Bearing Carrier (assembled)
c - Cover Nut (Tighten; DO NOT torque)
d - Bearing Carrier Removal Tool (91-46086A1)
e - Puller Bolt (91-85716); Torque to 45 lb. in. (5 Nm)

5. Fasten dial indicator to gear housing and Backlash Indicator Tool to driveshaft.
6. Recheck torque on puller bolt [45 Ib. in. (5 Nm)].
7. Position dial indicator pointer (on Backlash Indicator Tool) on line marked “1” if gear
ratio is 1.87:1 (15 teeth on pinion gear), on line marked “2” if gear ratio is 2:1 (14 teeth
on pinion gear) or on line marked “4” if gear ratio is 2.3:1 (13 teeth on pinion gear).
d

c
e a
b

51880
a - Thread Stud Adaptor (from 91-14311A1)
b - Stud
c - Backlash Indicator Tool (91-78473)
d - Dial Indicator Holder (91-89897)
e - Dial Indicator (91-58222A1)

90-855347R02 NOVEMBER 2002 Page 6A-37

RIGHT HAND NON-RATCHETING

8. Lightly turn driveshaft back-and-forth (no movement should be noticed at propeller

shaft).
9. Dial indicator registers amount of backlash which must be 0.018 in. to 0.027 in. (0.46
mm to 0.69 mm) for the 1.87:1 gear ratio, 0.015 in. to 0.022 in. (0.38 mm to 0.56 mm)
for the 2:1 gear ratio and 0.018 in. to 0.023 in. (0.46 mm to 0.58 mm) for the 2.3:1 gear
ratio.
10. If backlash is LESS than the specified minimum, REMOVE shims from in front of the
forward gear bearing race to obtain correct backlash. When reinstalling the pinion nut,
apply Loctite 271 on threads of nut.
11. If backlash is MORE than the specified MAXIMUM, add shims in front of forward gear
bearing race to obtain correct backlash. When reinstalling pinion nut, apply Loctite
271 on threads of nut.
NOTE: By adding or subtracting a 0.001 in. (0.025 mm) shim, the backlash will change
approximately 0.001 in. (0.025 mm ).
REVERSE GEAR
Determining Reverse Gear Backlash
Although reverse gear backlash is not adjustable, it may be checked as follows:
1. Propeller shaft and bearing carrier must be completely assembled and installed in
gearcase.
2. Install shift shaft in gearcase.
3. Shift gearcase into reverse.
4. Slide 6 in. x 1.5 in. I.D. (152.5 mm x 38.0 mm) piece of PVC pipe over propeller shaft
and position pipe against bearing carrier.
5. Secure pipe against carrier with propeller nut and tab washer.

b a

51866
a - Pipe [6 in. x 1.5 in. (152.5 mm x 38.0 mm)]
b - Propeller Nut
c - Tab Washer

6. Torque propeller nut to 45 lb. in. (5 Nm).

7. Gently rock driveshaft. Dial indicator should show backlash of 0.030 in.-0.050 in.
(0.762 mm- 01.27 mm).
If backlash is not as indicated, gearcase is not properly assembled or parts are excessive-
ly worn and must be replaced before returning gearcase to service.

Page 6A-38 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

Clutch Actuator Rod

REASSEMBLY
1. Place a small amount of 2-4-C with Teflon on actuator rod and install cam follower.
b a

a - Actuator Rod
b - Cam Follower

Shift Shaft Bushing

REASSEMBLY
1. Position shift shaft bushing on a press with threaded side down.
2. Apply Loctite 271 to outside diameter of oil seal.
3. Press oil seal into shift shaft bushing with lip of seal up.
4. Wipe any excess Loctite from oil seal and bushing.
5. Place rubber washer against oil seal.
6. Install O-ring over threads and up against shoulder of bushing.
7. Lubricate O-ring and oil seal with 2-4-C with Teflon.
Propeller Shaft
REASSEMBLY/INSTALLATION
1. Insert clutch actuator rod assembly into end of propeller shaft. Align cross pin slot in
actuator rod with cross pin slot in propeller shaft.
2. On production model gearcases, position sliding clutch onto propeller shaft with
grooved rings (on sliding clutch) toward propeller end of propeller shaft. Cross pin hole
and detent holes (in sliding clutch) must line up with cross pin slot and detent notches
on propeller shaft.

d g h
e
f

a 51864
b c
51864

a - Cam Follower
b - Propeller Shaft
c - Sliding Clutch
d - Grooved Rings
e - Cross Pin Hole
f - Detent Hole (Behind Finger and Thumb)
g - Detent Notch (One on Each Side)
h - Cross Pin Slot

90-855347R02 NOVEMBER 2002 Page 6A-39

RIGHT HAND NON-RATCHETING

3. Insert cross pin through sliding clutch, propeller shaft and actuator rod, forcing cross
pin tool out.
4. Apply a small amount of 2-4-C with Teflon on detent pin. Position a detent pin in detent
pin hole of sliding clutch with rounded end of pin toward propeller shaft.
b
c

51864 d 51864
a - Cross Pin
b - Detent Pin
c - Cross Pin
d - Sliding Clutch

5. Install cross pin retaining spring onto sliding clutch as follows:

IMPORTANT: DO NOT over-stretch retaining spring when installing onto sliding
clutch.
6. Spirally wrap spring into groove on sliding clutch.
7. Place gear housing in a soft jaw vise with the driveshaft in a vertical position.
8. Coat cam pocket of cam follower with 2-4-C with Teflon.
9. Place shift cam into cam pocket of cam follower with numbered side of cam facing up.
10. With shift cam positioned as shown, insert propeller shaft through forward gear until
shaft bottoms out.

b a

c
55095 e d
51864
a - Cam Pocket
b - Cam Follower
c - Shift Cam
d - Shift Cam (Position as Shown)
e - Gear Housing

Page 6A-40 90-855347R02 NOVEMBER 2002

 RIGHT HAND NON-RATCHETING

CAUTION
Until bearing carrier is installed into gear housing, extreme care MUST BE taken
not to apply any side force on propeller shaft. Side force on propeller shaft may
break the neck of the clutch actuator rod.
11. Insert shift shaft down shift shaft hole (of gear housing) and through shift cam and cam
follower. (It may be necessary to rotate shift shaft back-and-forth slightly for it to enter
shift cam.)
12. Apply a light coat of 2-4-C with Teflon to threads of shift shaft bushing. (Thread bush-
ing into position, but do not tighten down at this time)

51867
a - Shift Shaft Bushing
b - Shift Shaft

13. Lubricate O-ring on bearing carrier with 2-4-C with Teflon.

14. Apply a light coat of 2-4-C with Teflon to outside diameter of bearing carrier (where
carrier contacts gear housing).
NOTE: When performing Step 15, rotate driveshaft clockwise (viewed from top) to mesh
pinion gear with reverse gear.
15. Position bearing carrier over propeller shaft and slide it into gear housing. (Be sure
to align bearing carrier keyway with gear housing keyway.)
16. Push bearing carrier in as far as possible by hand, then install bearing carrier key.
17. Place tab washer against bearing carrier.
18. Apply 2-4-C with Teflon to threads of cover nut and install cover nut in gear housing
(verify that the word “OFF” and arrow are visible).

90-855347R02 NOVEMBER 2002 Page 6A-41

RIGHT HAND NON-RATCHETING

19. Start cover nut a few turns by hand, then using Cover Nut Tool and torque wrench,
torque cover nut to 210 Ib. ft. (285 Nm).

a
b
c

51871
a - O-ring
b - Cover Nut Tool (91-61069)
c - Torque Wrench

20. Bend one lock tab of tab washer into cover nut (only one will align).
21. Bend remaining tabs of tab washer toward front of gear housing.
22. Use Shift Shaft Bushing Tool (91-31107) and torque shift shaft bushing to 30 Ib. ft.
(41 Nm).
Water Pump
REASSEMBLY/INSTALLATION
1. Install oil seals into water pump base, as follows:
a. Place water pump base on a press.
b. Just before installing each seal apply Loctite 271 on outside diameter of oil seal.
c. With a suitable mandrel, press the smaller diameter oil seal into pump base with
lip of oil seal toward impeller side of base.
d. With a suitable mandrel, press the larger diameter oil seal into pump base with lip
of oil seal toward gear housing side of base.
e. Wipe any excess Loctite from oil seals and water pump base.

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2. Install O-ring into O-ring groove of water pump base. Lubricate O-ring and oil seals
with 2-4-C with Teflon.

c
b
51869
a - Mandrel
b - Oil Seal (Smaller OD)
c - O-ring Groove

3. Install divider block if removed. Use RTV 587 Silicone Sealer to seal seams between
divider block and gear housing.
4. Install a new water pump base gasket and install water pump base.

b c
51866

51870
a - Divider Block
b - Water Pump Base
c - Gasket
d - Hole (MUST be positioned as shown)

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5. Install the following in order: Pump base to face plate gasket, face plate gasket and
face plate to pump cover gasket. Gaskets and face plate are indexed by dowel pin
location and must be installed correctly.

b
c

51868
a - Gasket (Water Pump Base to Face Plate)
b - Face Plate
c - Gasket (Face Plate to Water Pump Cover)

6. Place impeller drive key on flat of driveshaft. Hold key on driveshaft with a small
amount of 2-4-C with Teflon.
IMPORTANT: When completing gear housing repair, that requires removal of water
pump impeller, it is recommended that the impeller be replaced. If it is necessary,
however, to reuse the impeller, DO NOT install in reverse to original rotation, or pre-
mature impeller failure will occur. Original rotation is clockwise.

CAUTION
A visual inspection of impeller drive key MUST BE made to determine that drive
key is on flat of driveshaft after impeller is installed. If key has moved off flat of
driveshaft, repeat Steps 7 and 8.
7. Slide impeller down driveshaft to impeller drive key. Align drive key with keyway in the
center hub of impeller, and slide impeller over drive key.
8. If removed, install new water pump insert into pump cover as follows:
a. Apply Perfect Seal to water pump insert area of pump cover.
b. Install water pump insert into pump cover. Verify that tab on insert enters recess
in pump cover.
c. Wipe any excess Perfect Seal from insert and cover.
NOTE: If 2 holes were drilled in top of the water pump cover to aid in removal of insert,
fill holes with RTV 587 Silicone Sealer or equivalent. Allow to cure for 24 hours prior to
operating engine.

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9. Install water tube seal into pump cover, being sure that plastic side of seal goes into
cover first.
10. Reinstall water tube guide into water pump cover.
11. Apply a light coat of 2-4-C with Teflon inside of water pump insert.
12. Position assembled water pump cover over driveshaft and lower over water pump
studs. Rotate driveshaft in a clockwise direction (viewed from top), while pushing
down on pump cover to ease impeller entry into cover.
13. Install water pump cover retainer washers, nuts and bolt.

CAUTION
DO NOT over torque nuts and bolt, as this could cause cover to crack during oper-
ation.
14. Torque water pump nuts to 50 Ib. in. (5.5 Nm), and water pump bolt to 35 Ib. in. (4 Nm).
15. Install centrifugal slinger over driveshaft and down against pump cover.

c
51874
a - Water Tube Guide
b - Water Tube Seal
c - Nuts, Bolt and Washers

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Gear Lubricant Filling Instructions

1. Remove any gasket material from Fill and Vent screws and gear housing.
2. Install new gaskets on Fill and Vent screws.
IMPORTANT: Never apply lubricant to gear housing without first removing Vent
screw, or gear housing cannot be filled because of trapped air. Fill gear housing
ONLY when housing is in a vertical position.
3. Slowly fill housing through Fill hole with Premium Gear Lubricant until lubricant flows
out of Vent hole and no air bubbles are visible.
4. Install Vent screw into Vent hole.
IMPORTANT: DO NOT lose more than one fluid ounce (30cc) of gear lubricant while
reinstalling Fill screw.
5. Remove grease tube (or hose) from Fill hole and quickly install Fill screw into Fill hole.
Installing Gear Housing to Driveshaft Housing
WARNING
Disconnect high tension leads from spark plugs and remove spark plugs from
engine before installing gear housing onto driveshaft housing.
1. Tilt engine to full up position and engage the tilt lock lever.
2. Apply a light coat of 2-4-C with Teflon onto driveshaft splines.

CAUTION
DO NOT allow lubricant on top of driveshaft. Excess lubricant, that is trapped in
clearance space, will not allow driveshaft to fully engage with crankshaft. Subse-
quently, tightening the gear housing nuts (while excess lubricant is on top of dri-
veshaft) will load the driveshaft/crankshaft and damage either or both the power-
head and gear housing. Top of driveshaft is to be wiped free of lubricant.
3. Apply a light coat of 2-4-C with Teflon onto shift shaft splines. (DO NOT allow lubricant
on top of shift shaft.)
4. Apply a thin bead of RTV 587 Silicone Sealer against the top of divider block.
5. Insert trim tab bolt into hole in rear of gear housing to driveshaft housing machined
surface.
6. Shift gear housing into forward gear and place guide block anchor pin into forward
gear position.

a
51900
a - Guide Block Anchor Pin

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7. Position gear housing so that the driveshaft is protruding into driveshaft housing.
NOTE: If, while performing Step 8, the driveshaft splines will not align with crankshaft
splines, place a propeller onto propeller shaft and turn it counterclockwise as the gear
housing is being pushed toward driveshaft housing.
8. Move gear housing up toward driveshaft housing, while aligning shift shaft splines and
water tube with water tube guide (in water pump cover).
9. Place flat washers onto studs (located on either side of driveshaft housing). Start a
nut on these studs and tighten finger-tight.
10. Start bolt at rear of gear housing inside trim tab recess. DO NOT tighten bolt at this
time.
11. Recheck shift shaft spline engagement and correct if necessary.
IMPORTANT: Do not force gearcase up into place with attaching nuts.
12. Evenly tighten the 2 nuts which were started in Step 9. Torque to listing in Torque
Specifications, preceding.
13. After 2 nuts (located on either side of driveshaft housing) are tightened, check shift
operation as follows:
a. Place guide block anchor pin into forward gear position. Rotate flywheel clockwise
(viewed from top); propeller shaft should rotate clockwise.
b. Place guide block anchor pin into neutral position. Propeller shaft should rotate
freely clockwise/counterclockwise.
c. Place guide block anchor pin into reverse gear position. Rotate flywheel clockwise
(viewed from top); propeller shaft should rotate counterclockwise.
IMPORTANT: lf shifting operation is not as described, preceding, the gear housing
must be removed and the cause corrected.
14. Install washers and nuts onto studs (located on bottom center of anti-cavitation plate).
Torque to listing in Torque Specifications, preceding.
15. Install special flat washer and nut on stud at leading edge of driveshaft housing.
Torque to listing in Torque Specifications, preceding.
16. Torque bolt (started in Step 10) to listing in Torque Specifications, preceding.
17. Install trim tab, adjust to position in which it had previously been installed, and tighten
securely.
18. Install plastic cap into trim tab bolt opening at rear edge of driveshaft housing.

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Propeller Installation
WARNING
When installing or removing propeller, because of the engine’s ease in starting,
be sure that the remote control is in neutral position and that the key switch is
“OFF.” Place a block of wood between the anti-cavitation plate and propeller to
prevent accidental starting and to protect hands from propeller blades while re-
moving or installing nut.
1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with
one of the following products:
-- Anti-Corrosion Grease
-- Special Lubricant 101
-- 2-4-C Marine Lubricant
-- Perfect Seal
2. Place forward thrust hub over propeller shaft with shoulder side toward propeller.
3. Place propeller on propeller shaft and slide it up against thrust hub.

51866
a - Forward Thrust Hub
b - Propeller Shaft

4. Place continuity washer (if equipped) onto shoulder of rear thrust hub.
5. Place rear thrust hub, tab washer and propeller nut on propeller shaft.
6. Thread propeller nut onto propeller shaft until nut is recessed into tab washer.
7. After propeller nut is recessed into tab washer, tighten nut securely [minimum of 55
Ib. ft. (74.5 Nm) torque].
8. Bend 3 of the tabs of tab washer down in grooves of rear thrust hub to secure propeller
nut. (If tab washer tabs do not align with slots, continue to tighten propeller nut to ob-
tain alignment. DO NOT loosen nut to align tabs.)

CAUTION
DO NOT misinterpret propeller shaft movement with propeller movement. If pro-
peller and propeller shaft together move forward and aft, this is normal; however,
propeller should not move forward and aft on propeller shaft.

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9. After first use, retighten propeller nut and again secure with tab washer (Steps 7 and
8, preceding). Propeller should be checked periodically for tightness, particularly if a
stainless steel propeller is used.

a b

c
51866
a - Continuity Washer (if Equipped)
b - Rear Thrust Hub
c - Tab Washer
d - Propeller Nut

90-855347R02 NOVEMBER 2002 Page 6A-49